Front Fuel Feed, Return and Purge Line
TOOLS REQUIRED^ J 37088A Fuel Line Disconnect Set
^ SA9805E Fuel Line Separator
REMOVAL
NOTE: Fuel/Vapor lines cannot be spliced or repaired. The line must be replaced (if damaged) with the same type of line.
1. Position vehicle on hoist.
CAUTION: ANY TIME THE FUEL SYSTEM IS BEING WORKED ON, DISCONNECT THE NEGATIVE BATTERY CABLE, EXCEPT FOR THOSE TESTS WHERE BATTERY VOLTAGE IS REQUIRED.
2. Disconnect negative battery terminal.
CAUTION: DO NOT ALLOW SMOKING OR THE USE OF OPEN FLAMES IN THE AREA WHERE WORK ON THE FUEL SYSTEM IS TAKING PLACE.
3. Relieve fuel system pressure. Refer to "Fuel System Pressure Relief".
CAUTION: WHENEVER FUEL LINES ARE REMOVED, CATCH FUEL IN AN APPROVED CONTAINER. CONTAINER OPENING MUST BE A MINIMUM OF 300 MM (12 IN.) DIAMETER TO ADEQUATELY CATCH THE FLUID.
4. Disengage front fuel feed and return lines at fuel rail using Fuel Line Disconnect Set J 37088A. Remove fuel line bracket bolt.
5. Disengage EVAP canister purge line underhood (located near top of passenger's side strut tower) using Fuel Line Separator SA9805E.
IMPORTANT: To facilitate removal, it may be necessary to spray quick connects with penetrating oil to remove debris.
6. Remove lines from retaining clips.
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.
7. Raise vehicle to a comfortable working height.
CAUTION: NEVER DRAIN OR STORE FUEL IN ANY OPEN CONTAINER DUE TO THE POSSIBILITY OF FIRE OR EXPLOSION.
8. Disconnect front fuel feed, return and front EVAP canister purge lines from the chassis fuel feed, return and EVAP canister purger lines located near passenger front wheel well.
9. Release underbody retaining clip.
10. Remove necessary lines.
INSTALLATION
CAUTION: IF FUEL LINES WERE DISCONNECTED AT CONNECTORS, LUBRICATE STEEL LINE MALE ENDS WITH CLEAN ENGINE OIL. HOLDING STEEL LINE FIRMLY, PRESS ON FEMALE COUPLER UNTIL CLICK IS HEARD. THEN PULLBACK TO CONFIRM ENGAGEMENT. PINCHED, KINKED OR DAMAGED FUEL AND VAPOR LINES MUST BE REPLACED.
NOTE:
^ Plastic retainers must be replaced when fuel lines are disassembled. Install new retainer into female cavity. Care must be taken to ensure that locking tab is centered in window of female cavity. Firmly press female connection onto male end until a click is heard, then pull back to confirm engagement.
^ Fuel lines cannot be spliced. If damaged, they must be replaced with the same type of line.
1. Make sure lines are not kinked, bent, or damaged.
NOTE: Replace plastic fuel line retainers whenever fuel supply lines are disconnected at fuel filter and fuel rail. Install new retainer into female portion of connection. Care must be taken to assure that locking tab is centered in window of female connection. Firmly press male and female portions together until a "click" is heard, then pull firmly back to confirm engagement.
2. Install fuel and vapor lines. Make sure the lines are properly routed. Attach the fuel line connectors at both ends. Connect the vapor line at both ends.
NOTE: All nuts that are corroded or damaged must be replaced to ensure fuel line retainers do not come loose from the vehicle's body.
3. Clip fuel and vapor hoses in place. Install fuel line bracket and bolt.
Torque:
Fuel Line Bracket and Bolt: 10 N.m (89 in-lbs)
4. Install underbody retaining clip. Hammer on studs with rubber mallet.
5. Lower vehicle.
6. Connect battery negative terminal.
Torque:
Battery Terminal Bolts: 17 N.m (13 ft-lbs)
7. Prime fuel system.
7.1 Cycle ignition On for 5 seconds and then Off for 10 seconds.
7.2 Repeat step 7.1 twice.
7.3 Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
7.4 If engine does not start repeat steps 7.1-7.3.
8. Start engine and check the system for leaks.